Boxit Corporation - Review of Kitting Operations

             July 26, 2015

Proposal submitted by Albion Services to Boxit Corporation:  Review of Kitting Operations (word count: ~1000 words)

Introduction

Boxit is facing the challenge of dramatically expanding the output of its kitting process. We propose conducting a review of kitting operations at Boxit’s Galway, Ireland plant to determine the most cost effective way to both streamline and expand the process. Albion will also suggest steps that can be taken to ensure successful implementation. The project will provide a total of 9 days of consulting, including visiting the Galway plant and performing a detailed data analysis, for a fixed professional fee of $16,320 plus expenses estimated to be $2800 to $3200. The proposed project will enable Boxit to intelligently expand its operations to meet the increased demands of its customers in both process cost and quality.  We predict that our will xxxx.

Statement of Problem

Boxit provides kitting of PC peripherals to supply ACME computer factory in Ireland. The kitting is done on eight lines and operates in parallel to ACME’s building of the PC.  Kits must merge with ACME orders at a precise time and place flawlessly.  ACME feeds Boxit a stream of live orders and Boxit is delivering kits to ACME every 20 minutes.  Boxit is facing the challenge of dramatically expanding the output of this process.

Objectives and Scope

This project will entail a review of the manufacturing processes used by Boxit to assemble the kits for ACME.  It will include reviewing receipt of orders, assembly, replenishment, stocking, packing, labeling and other activities involved in kitting.  It will be limited to the Galway plant.  It will focus on the processes and automation used. Some information systems requirements will be included in the review, but a detailed review of the IT support for kitting will not be included in this project.

Methodology

We propose performing a short concentrated review of the kitting operations to quickly identify any major opportunities for streamlining and expanding the processes.  Detailed implementation assistance can follow later as desired.

Albion will attack the problem from two different directions: 1) Plant visit and interviews and 2) Data analysis.

Plant Visit and Interviews

John Merriwether, Albion’s VP of Engineering and Supply Chain Consulting, will visit and tour the plant in Galway.  He will interview the plant operations and engineering staff and become familiar with the design and operation of the kitting lines.  He will work with the plant staff to flow chart the processes indicating the cycle times, takt times, error rates, etc.  He will collect and review available data on flow rates, peak loads, backlogs, queue times, line changeover time, material staging times etc.  He will meet and work with plant staff to brainstorm new ideas for streamlining the operations.